Product and equipment location and automation system and method

ABSTRACT

A system for location of assets on a premises is described. The system uses identifiers attached to a group of one or more assets along with mobile sensor packages. Each mobile sensor package contains components for data processing, data exchange, and storage. The sensor package also contains a sensor for reading identifiers and a location tool. The mobile sensor packages are attached to each mover of assets on the premises.

PRIORITY CLAIM

The instant application claims priority as a continuation in part ofU.S. application Ser. No. 15/965,472, filed on Apr. 27, 2018, presentlypending, which in turn was a continuation in part of application Ser.No. 14/985,199 filed on Dec. 30, 2015, abandoned on Apr. 27, 2018, whichin turn claimed priority as a non-provisional of U.S. ProvisionalApplication Ser. No. 62/230,132 filed on May 28, 2015, presentlyexpired, the contents of each of which are incorporated herein byreference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The field of the invention is a locating or tracking system for tangibleobjects (such as inventory, reagents, medicines, other products, andpersonnel) designed to automate distribution tasks within an enclosedspace where traditional location technologies are not operable.

2. Background of the Invention

In various embodiments, the invention provides a multi-tier locationsystem capable of real-time location and identification of assets withinan enclosed space, such as a warehouse.

In one embodiment, the invention comprises a system which uses a largenumber of low-cost identification tags for individual assets, a densearray of readers which track the low-cost tags, and a top level logictier which analyses the data from the readers.

Traditionally, fulfillment centers have incorporated tracking only forhigh-value assets and on an ad hoc basis with manual and work-intensivescanning of identifiers such as bar codes. In such systems, real-timetracking is implemented for only a subset of the tracked inventory, ifat all. In the instant invention, the operator of a facility can trackany identified item, using low cost devices, in real-time with aknowable level of precision.

A need exists in the art for a system that tracks items in locationswhere conventional location techniques are not functional or do notprovide sufficient granularity.

SUMMARY OF INVENTION

An object of the invention is to create a device and method for trackingof assets within the premises. An advantage of the invention is that itallows for real-time control of inventory, machinery, and other assets.

Another object of the invention is to provide reliable locationinformation in environments where traditional location technologies donot function. A feature of the invention is that it employs a multi-tiersystem to provide location information for tagged assets. An advantageof the invention is that it allows for location of assets indoors and inother environments where traditional location technologies cannot beimplemented.

Yet another object of the invention is to provide information whilerelying on simple and inexpensive identification tags. A feature of theinvention is that the first tier of the system relies on passive RFIDtags requiring little to no customization. An advantage of oneembodiment is that the system can be scaled without incurring high costsper item.

A further object of the invention is to provide a system whereinlocation of a tagged asset is ascertained reliably. A feature of theinvention is that in one embodiment multiple tiers of the system areused to reliably locate any one given tag. An advantage of the system isthat it facilitates asset location while using multiple simultaneousreadings from each tag.

Another object of the invention is to provide a system with redundancyfeatures. A feature of the invention is in one embodiment, a multitudereaders form an array of readers. A benefit of the invention is that asingle point of failure does not exist within the system.

An additional object of the invention is to provide a system which canread asset identification tags in environments which includeinterference or which suffer from signal distortion. A feature of theinvention is that the array of readers results in tags being detected ineven difficult conditions. A benefit of the system is that assets arenot misidentified and can be accounted for with known levels ofprecision.

A further object of the invention is to provide detailed analysis ofdata from many sources. A feature of the system is that in oneembodiment a third layer of the system provides logic and analysis toolsto convert raw data into actionable reports. A benefit of the system isthat it gathers readings from many sensors simultaneously and providesactionable information from the raw sensor readings on demand or inreal-time.

An additional object of the invention is to provide a system capable ofbeing adapted to various environmental difficulties. A feature of theinvention is that the design and layout of the reader sensors may becustomized to account for problematic features within the environment ofthe asset tracking system. In one embodiment of the invention, theinterference, number of readouts required, and other parameters are usedin designing the layout of the middle tier of the system. A benefit ofthe system is that it is flexible and can be applied to demandingscenarios.

A further object of the invention is to provide a system which relies onpower-efficient components. A feature of the invention is that, in oneembodiment, several of the tiers use passive components and activecomponents that do not draw large amounts of current. A benefit of theinvention is that the many of the components do not require powersources and the tiers that require powered components can use long-lifebatteries and other convenient power sources.

An additional object of the invention is to create a tracking systemwhich does not add manual steps or overhead to the asset managementtasks. A feature of the invention is that the need for manual scanningor physical confirmation of inventory is obviated. A benefit of theinvention is that a system incorporating an embodiment of the inventioncan be run automatically.

A further object of the invention is to facilitate a large scaledeployment of a tracking system. A feature of the invention is that thesystem components can be scaled to any real-world scenario. A benefit ofthe invention is that the system may be deployed to account forlocations of all assets in an environment.

An additional object of the invention is to provide a way to trackdissimilar products. In one embodiment, a feature of the invention isthat the tagging of assets can be done using a number of different tags,depending on the type of asset to be tagged. A benefit of the system isthat it allows for flexibility in selecting type of lowest levelidentification tags.

A system for location of assets on a premises comprising an RFID tagattached to an asset to be tracked; an array of RFID tag readers placedin known locations within said premises wherein said RFID tag readersactivate and obtain tag information from each tag; and a control logicwherein said control logic reads information from said array of RFIDtags; wherein said control logic triangulates the position of eachtracked asset.

BRIEF DESCRIPTION OF DRAWING

The invention together with the above and other objects and advantageswill be best understood from the following detailed description of thepreferred embodiment of the invention shown in the accompanyingdrawings, wherein:

FIG. 1 depicts an overview of a prior art system;

FIG. 2 depicts an overview of one embodiment of the invention;

FIG. 3 depicts a detailed view of one tier pursuant to one embodiment ofthe invention;

FIG. 4 depicts a schematic of one embodiment of the invention;

FIG. 5 depicts a schematic of a different embodiment of the invention;

FIG. 6 depicts a data packet which is received by a tier of the systemin one embodiment of the invention;

FIG. 7 depicts an overview of one embodiment of the invention;

FIG. 8 depicts a schematic overview of another embodiment of theinvention;

FIG. 9 depicts another overview of one embodiment of the invention;

FIG. 10 depicts a component of one embodiment of the invention;

FIG. 11 depicts a data flow within one embodiment of the invention;

FIG. 12 depicts a network communications pattern pursuant to oneembodiment of the invention;

FIG. 13 depicts information processing details, pursuant to oneembodiment of the invention;

FIG. 14 depicts an alternative embodiment of the invention in afacility;

FIG. 15 depicts an alternative embodiment of a component used in thesystem; and

FIG. 16 depicts a further alternative embodiment.

DETAILED DESCRIPTION OF THE INVENTION

The foregoing summary, as well as the following detailed description ofcertain embodiments of the present invention, will be better understoodwhen read in conjunction with the appended drawings.

To the extent that the figures illustrate diagrams of the functionalblocks of various embodiments, the functional blocks are not necessarilyindicative of the division between hardware circuitry. Thus, forexample, one or more of the functional blocks (e.g. processors ormemories) may be implemented in a single piece of hardware (e.g. ageneral purpose signal processor or a block of random access memory,hard disk or the like). Similarly, the programs may be stand-aloneprograms, may be incorporated as subroutines in an operating system, maybe functions in an installed software package, and the like. It shouldbe understood that the various embodiments are not limited to thearrangements and instrumentality shown in the drawings.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralsaid elements or steps, unless such exclusion is explicitly stated.Furthermore, references to “one embodiment” of the present invention arenot intended to be interpreted as excluding the existence of additionalembodiments that also incorporate the recited features. Moreover, unlessexplicitly stated to the contrary, embodiments “comprising” or “having”an element or a plurality of elements having a particular property mayinclude additional such elements not having that property.

Turning to the figures, FIG. 1, depicts a prior art approach 10 forsingle-point tracking. In the prior art approach 10, a series of tagreaders 18, 20, 22, 24 are placed in strategic locations in a facility.As shown in FIG. 1, the strategic location is defined by the outer wall12 which includes a pair of doors. Inventory from the facility is beingtransported using a first forklift 14 and a second forklift 16.

The first forklift 14 is approaching the first door which is surroundedby the first 18 and second 20 tag readers. The second forklift 16 isapproaching the second door, which is surrounded by the third 22 andfourth 24 tag readers. In an optimum scenario under the prior artsystem, all the tags carried by the first forklift 14 would be read byeither the first reader 18 or the second reader 20. Likewise all thetags carried by the second forklift 16 would be read by the third reader22 and the fourth reader 24. In reality, however, there is cross-over inthe tag readouts. As such, some of the tags on the first forklift 14will mistakenly be read by the third 22 or fourth 24 readers.Conversely, some of the tags on the second forklift 16 will bemistakenly read by the first 18 and second 20 reader. Furthermore, someof the tags will be read by none of the four readers.

If a tag is read by the unintended reader then it may be identified ashaving been transported with the incorrect shipment. Such incorrectreadings result in lost inventory and often require manual checking ofcargo. Tags which pass unread also create problems of maintainingcorrect inventory.

In real-world scenarios the prior art system 10 depicted in FIG. 1 wouldbe capable of correctly identifying the point and time of departure forabout 90% of the inventory leaving the facility.

Prior art approaches use readers 18, 20, 22, 24, which are bulky andexpensive. Further, the prior art readers 18, 20, 22, 24 can interfereand compete with one another. The readers act as independent devices andso adding more readers results in diminishing benefits, while the costsremain high. In some prior art approaches, each reader costs more than$1000.

Given the cost of incorporating readers 18, 20, 22, 24 into the system,prior art approaches have only a few strategic locations where thereaders are found. In the embodiment of FIG. 1, the system is only ableto detect once inventory is leaving the facility. For example, there isno way to detect the path that the first forklift 14 took in approachingthe wall 12. As such, the prior art system 10 is not readily useable forinventory tracking within the facility.

In order to address these shortcomings, most prior art systems 10 addmanual checks and additional identification tasks which use non-RFIDbased systems, such as optical scanners, image detection, bar codes, andthe like. The result is that prior art systems 10 are complicated,expensive, and yet lack tracking features that would add value to thebusiness process.

Three Tier Design

As shown in FIG. 2, the invented system 50 comprises three logicallayers 52, 54, 56, in one embodiment, that overcomes the drawbacks ofthe prior art. The system uses a logic layer 52 to manage the remainingcomponents. In communication with the logic layer 52 is the reader layer54. Members of the reader layer 54 activate and read the identifiers ofthe tag layer 56.

As shown in FIG. 2, the logic layer 52 comprises at least one logiccontroller 62. The logic layer 52 further includes at least one datastore 58 and at least one user interface 60. In one embodiment, thelogic controller 62, data store 58, and at least one user interface 60are implemented in a single system, such as a server having access to adatabase management software and an interface, such as a web-basedreporting interface which generates reports on the basis of informationfound in the data store 58. The logic controller 62, however, is not apassive device, in one embodiment, and performs calculations on the datastored in the data store 58, such as triangulation discussed supra.

In another embodiment, the logic controller comprises distributingcomputing resources in communication with one another with data store 58shared between the computing resources and resulting user interface 60.In one embodiment, the logic controller 62 is physically located in thesame facility as the rest of the system components, in anotherembodiment, the logic controller 62 is located at a physically remotesite.

The reader layer 54 of the system comprises a network of RFID readers(designated with the letter R in the schematic). As shown in FIG. 2, theRFID readers of the reader layer 54 are in two-way communication withthe logic controller 62 of the logic layer 52. In the embodiment shownin FIG. 2, one of the readers 64 is in direct communication with thelogic controller 62, while another reader 66 is communicating with thelogic controller 62 indirectly, that is by first passing its data to thedirect contact reader 64.

The system 50 also includes the tag layer 56. The tag layer 56 compriseslarge sets of tags (depicted as T in FIG. 2). In one embodiment, thesystem 50 provides for reading and management of thousands of tags.

As each tag or sets of tags moves to proximity of a reader R, a tag 68 Twill become activated and be read by a reader R.

Readers R of the reader layer 54 transmit to the logic controller 62information including the identifier of the tag T being read by thereader R as well as the signal strength of the reading of the tag T.

For purposes of clarity of FIG. 2, the tags are shown as physicalseparated from the readers R. In use, the tags T should be in frequentcommunication with readers R with few areas of the facility not coveredby a detection field of a reader R. Further, while the tag 62 beinginterrogated 68 by the reader R is shown as being interrogated by asingle reader, in practice multiple readers may be interrogating thesame tag in close proximity to one another.

The communication between the reader layer 54 and the logic layer 52 isaccomplished using wireless media, in one example. Each reader Rcomprises an antenna to activate the tag T as well as an antenna tocommunicate with the logic controller 62. In one embodiment bothantennas use Bluetooth. In another embodiment, Bluetooth or BluetoothLow Energy (le) is used to activate the tag T while a WIFI connection isestablished in order to communicate with the logic controller 62.

Tags

In one embodiment, the tags comprising the tag layer 56 are attached toall items to be tracked within the system. The assets to be trackedinclude trays, compartments, totes, ID cards of staff members, vehicles,actuator arms, and other components. In one embodiment, the tags T areattached using a removable adhesive. For some assets, the tags T includeautonomously broadcasting elements. While in most applications eachtracked item has its own tag T, in other applications certain containershave multiple tags T. For example, in one embodiment totes designed tostore multiple items have multiple tags.

The tag layer 56 allows for tracking of any asset, not merely high-valueitems. The tag layer 56 can be used to track the entire inventory of awarehouse, components used in a process, and others. In one embodiment,the tag layer 56 is used to track the use level of an expendable item,such as amount of medicine in a container. In this embodiment, the taglayer is used to indicate whether the item is empty, expired, damaged,or other status, based on the tracked item's pattern of use, itsproximity to other equipment and other parameters.

In one embodiment, a passive tag T includes am Ultra High Frequency(UHF) antenna which is activated by a radio-frequency field generated bya reader, and a response signal is broadcast upon activation. In oneembodiment, some tags are self-powered and send a response signal uponreceiving the appropriate signal from a reader.

In one embodiment, the tags cost between $0.10 to 0.50 per unit and eachtag has a broadcast range of 3 to 30 feet. Each tag has a useable lifeof 5 to 10 years.

Readers

The reader layer 54 comprises a set of readers R, as shown in FIG. 2. Inone embodiment, the location of the readers R is determined on basis ofreal-world performance characteristics of the physical location wherethe system is being implemented. For example, in some embodiments, aspart of the layout of readers R, measurements of interference arecompleted.

Turning to FIG. 3, depicted therein is one arrangement of the readerlayer 54. The reader layer 54 comprises an array 80, 82 of individualreaders 84.

As shown in FIG. 3, the first array 80 of readers comprises an array of4 by 7 readers for a total of 28 readers. The second array 82 likewisecontains 28 readers. As each forklift 88, 90 traverses the array 80, 82,the tags held on the forklift 88, 90 are read by several readers 84. Thereaders then forward the data to the logic controller 62 (not shown inFIG. 3).

The reader layer 54 is customizable in that areas of the facility whichare inaccessible to product, such as closed off areas 86 do not requirereader tags to be placed therein. The density of the first array 80 andthe second array 82 is set to correspond to the maximum velocity of thefirst 88 and second 90 forklift. In one embodiment, the operator of therespective forklift 88, 90 is notified if the speed of traversal of thearray 80, 82 exceeds the maximum speed rating.

In the embodiment shown in FIG. 3, the readers are placed in an arraysuch that at any given time the products on each forklift are incommunication with at least six readers 84. In one embodiment, the griddefined by either array 80, 82 has individual reader 84 within 30 feetof one another, as required to activate the UHF tags discussed infra.

The density of the array 80, 82 is determined in response tointerference, type of product to be tracked, and activity beingperformed in a given area. For example, grid patterns are used for thefollowing products:

Product Containers Comprising Primarily Dry Goods Metallic or MagnetizedComponents High Value Medical Products Slow Moving Bulky Containers

As can be appreciated, the amount of expected interference is animportant factor in designing the array 80, 82. However, the grid cannotbe too dense by having too many individual readers 84. This wouldincrease the cost of covering a warehouse or other facility, and wouldresult in interference.

In one embodiment, the individual reader 84 comprises a low cost activeelement comprising a UHF activation system and a simple communicationsystem for transmitting data to the logic controller 62.

In one embodiment, the readers 84 comprise a Bluetooth LE sensor with a330 foot range and a cost of $20 to $100 per unit. The reader 84includes a non-rechargeable battery, but it is user replaceable.

In one embodiment, each reader 84 includes a standards-compliant networkand management interface such as the Zigbee communication protocol. Inone embodiment, the readers 84 forward information from each other tothe logic controller 62 using a mesh routing protocol. In oneembodiment, the information transmitted by each reader 84 is encrypted.

Logic Layer Embodiments

The logic layer 52 receives data from the individual readers 84. Thelogic layer 52 includes at least one logic controller 62. In oneembodiment, the logic layer also comprises a number of intermediarydevices which collect data from the individual readers 84. The logiclayer 52 is responsible for turning the data received from theindividual readers 84 into actionable reports.

In one embodiment, shown in FIG. 4, the logic layer 52 comprises aserver 100 and at least one handheld device 102. The handheld deviceinterfaces with the server and assists in the communication with the tagreaders 104. The tag readers 104 are in intermittent communication withthe tags 106. The handheld device 102 does not read the individual tags106.

A handheld device 102 may also communicate directly with the readers104, as shown in FIG. 5.

Although exemplary implementations of the invention have been depictedand described in detail herein, it will be apparent to those skilled inthe relevant art that various modifications, additions, substitutions,and the like can be made without departing from the spirit of theinvention and these are therefore considered to be within the scope ofthe invention as defined in the following claims.

The triangulation of signals is performed by the logic layer 52 bycompiling signal strength readings from individual tags as they pass inproximity to particular readers 84.

In one embodiment, the location of all readers 84 is mapped as aninitial step in the design of the system.

Data Transmission Details

The details of the data being transmitted by each of the tags is shownin FIG. 6. A sample data packet of the data sent from a tag to a readercomprises a header 122 and a payload. The payload includes a tagidentifier 124 and a signal strength value 126.

Upon being received by a reader, the data packet 120 is forwarded to thelogic controller by the receiving reader. The data packet from thereader 128 comprises a similar header 130 and payload. The payload inturn comprises the tag identifier 132, signal strength value 134 andreader identifier 136.

While in FIG. 6 the information is shown as being sent as a singlepacket, in various embodiments the information is sent using payloadshaving many packets. In one embodiment, the header 122 of the tag packet120 is different from the header of the reader packet 128 inasmuch asthe tag packet 120 is not addressed to a specific reader.

In one embodiment, the signal strength value 126, 134 includes a timestamp for the signal strength measurement. In another embodiment, thetime value is stored in the header 122, 130.

Triangulation Details

In one embodiment, multiple readings of the signal strength values 134received from the reader data packet 128 are used to triangulate thelocation of a tag. In one embodiment, as the number of readersincreases, the triangulation becomes more precise.

In one embodiment, in order to triangulate a tag the logic controller 62compares the signal strength value of the tag with neighboring tags,especially where one of the neighboring tags has already beentriangulated.

In one embodiment, the triangulation results include both a location ata given time as well as a direction of movement.

Communication Details

The details of communication between the various layers are depicted inFIG. 7. The depicted embodiment 150 of the system comprises a server 152in communication with the reader nodes 156 using a wireless network 154.The wireless network, as shown in FIG. 7 comprises a Zigbee802.11-compliant network. The wireless network 154 is received by eachnode 156. As shown in FIG. 7, the wireless network 154 operates onshared media, such as wireless spectrum, but each node 156 has aconnection to the server 152. The reader node 156 connection 154 to theserver 152 is constant and directed, unlike the tag signal network 162which is intermittent and the signals sent by the tags are not addressedto any particular reader 156.

Each reader node 156 comprises a processor unit 158, which in turncomprises a data exchange bus, central processing unit, and memory(individual components not shown). The bus connects the processor unit158 to the mixed signal interface 160. The server 152 connection 154 isalso coupled to the central processor. In instances where the connection154 is not available, readings from the mixed signal receiver 160 arestored in cache memory within the processor unit 158. However, as thesystem is designed for real-time analysis, the data in cache memory isnot stored indefinitely and has an expiration date and time for when anode 158 is isolated from a server 152 connection (either a directconnection or a connection through a neighbor node).

The mixed signal receiver 160 provides an energizing radio frequencysignal 164. Upon being energized, the node 166 broadcasts an identifiersignal 162. In the depicted embodiment, the identifier signal 162 andthe energizing signal 164 are broadcast over a wide area and arereceived by as many different tags 166 and receivers 160 as possible.

Additional Embodiments

An overview of another embodiment 200 is shown in FIG. 8. The embodiment200 generally operates within a facility 215 which contains storageareas 210 and one or more mobile inventory manipulators or movers 205.

In one embodiment a mover 205 is an autonomous mobile robot. In anotherembodiment, a mover comprises a forklift, a cart, a pallet with wheelsor even facility 215 staff members, or any combination of the above.Each mover 205 includes the ability to move within the facility 215 aswell as having on-board storage for inventory. The purpose of each mover205 is to take inventory from a first storage area 210 to either adifferent storage area 210 or to a different location within thefacility 215, such as a loading dock or automation module.

A primary attribute of the embodiment 200 is that the location of eachmover 205 can be determined at any time t using the physical locationmeans described below. The contents of each mover 205 is known at thetime t. On the basis of that data, an embodiment of this system tracksthe contents of each facility 215 storage area 210. Therefore, thesystem 200 allows for accurate inventory management throughout theoperation of the facility 215, at any arbitrary time t, and not onlyduring the times that a confirmatory inventory check has taken place.

The tracking of each mover 205 is accomplished using sensors added toeach mover 205. The embodiment 200 as described below can trackinventory as it moves within the facility 215 to within +/−12 inches(approximately 30 cm). The embodiment 200 employs inexpensive hardwarewhich can be deployed in a limited time frame. Nonetheless, theembodiment 200 provides for high accuracy in identifying and tracking ofinventory and can locate inventory in three dimensions and can track itsposition with respect to time. Therefore, the embodiment both locatesinventory by recording its position in three dimensions as well astracking inventory as it changes position in time. In one embodiment, areport generated by the system is a path taken by particular inventorythrough the facility over time.

The embodiment 200 can be permanently added as a feature to a facility215 or it can be leased as needed. In this way, the embodiment 200 cancreate a recurring revenue stream by providing a high precisioninventory location as a service for a facility 215. The system can alsobe controlled, so that in one embodiment, complete tracking is onlyperformed for some periods of time, such as when high value items aremoving through the warehouse, or if there have been incidents ofinventory theft at a particular location.

While in the embodiment shown in FIG. 8, the storage areas 210 aredepicted as unitary objects, in a modern warehouse, the storage areascomprise multiple means of storing individual inventory items, such astrays, totes, boxes, pallets, carts. In one embodiment, the system 200is informed of the appropriate mover 205 to interact with a particulartype of storage area 210. For example, a forklift mover 205 would bedeployed to retrieve a pallet from a storage area 210. In oneembodiment, the choice is made by external software wherein the externalsoftware uses a series of sensors and set preferences to select theappropriate mover. In another embodiment, the system 200, includes themover 205 selection algorithm.

As shown in FIG. 9, the details of a storage area 210 is shown. Thestorage area includes at least one inventory item 212. The inventoryitem 212 requires tracking. The inventory item 212 includes ashort-range passive identifier 214 such as a passive RFID tag. Theshort-range passive identifier 214 contains a unique identifier andother information about the inventory item 212, such that when a mover205 interacts the inventory item 212, the status of the inventory item212 is known.

The passive identifier 214 is a passive RFID tag, in one embodiment. Thecorresponding reader on the mover only needs to interact with theidentifier 214 at the time the inventory item 212 is undergoing motion.It is not necessary to read the passive identifiers while the inventoryitem 212 is stationary.

While a passive RFID tag is used in one embodiment, other passiveidentification means are possible, such as printed two-dimensional barcodes, image verification, and others. The key requirement is that thepassive identifier 214 must be unique and must be capable of reliablereading by the mover interacting with the item 212.

Technologies such as passive RFID tags can be used to uniquely identifyitems, but are a poor choice for determining accurate positions of itemsin large scale complex physical environments, such as a factory floor ora warehouse filled with steel racks that interfere with the short rangesignals. However, as in this embodiment 200, each mover identifies theinventory item 212 once the item is being moved, a passive short rangeidentifier 214 is optimal as it allows for unique identification of aninventory item. In another embodiment, the item 212 is tracked andverified at continuous times. A different system, described below, isused for tracking of position.

In one scenario each mover reads and identifies tags on an inventoryitem. In another use scenario each mover reads and identifies acontainer carrying at least one inventory item, or an empty container,or some combination of empty containers and containers carryinginventory. In the container-based scenario, the system tracks individualcontainers. An external data store of container contents is used totrack individual items. In one embodiment this container contents datastore comprises a database populated with inventory information by theprovider of the containers. In either scenario, the system's end usercan deduce what inventory the mover is carrying and by tracking theposition of the mover provided by the system with respect to time. Inthis way, the system assists in tracking inventory in motion, even ifthe individual items are stored in larger containers.

The mover 205 interacting with the storage area 210 inventory item 212includes a mobile sensor package 220, which allows the mover 205 to bothidentify the inventory item 212 as well as report the position of theinventory item 212 as it moves with the mover 205 throughout thefacility. The details of the sensor package 220 will be described below.

Mobile Sensor Package

As shown in FIG. 10, the sensor package 220 includes a number of inputand output systems. The sensor package communicates with a base station250, which in turn relays information over a network 260 to a centralserver 270. One or more users 272 interact with the server 270 using thenetwork 260.

The users 272 are able to review the inventory status of the facilityand, in one embodiment, can request that automated systems confirm thelocation of certain inventory items having tags 214. In anotherembodiment, the users 272 will receive alerts about unexpected behaviorof the inventory or if the inventory is not meeting targets, such asbeing ready for pickup at a warehouse dock. In another embodiment, theusers 272 can request that the automated system download data to theuser 272's computer system, various data about some or all of theinventory or some or all of the containers, permitting user 272 toanalyze the data in various ways, including custom analyses.

The sensor package 220 includes components 222 for reading the inventorytags 214. In the depicted embodiments, the reader components 222 includea pair of signal switches 224, as the SP4T switches available fromAnalog Devices of Schaumburg, Ill. The reader components 222 furthercomprise two arrays of antennas 226, 228. The arrays of antennas 226,228 are controlled by the switches 224 to read different types ofinventory tags 214, in one embodiment. In another embodiment, theswitches 224 operate the antennas 226, 228 in such a way as to preventinterference and obtain highest quality signal, ensuring reliable andnoise-free reading of the inventory tags 214.

While the reading components 222 shown in FIG. 10 comprise readers ofRFID tags 214, other forms of inventory item identification are used inother embodiments. In other embodiments, not shown, the readingcomponents 222 include a camera, a laser scanner, and a chemical sensor.

The reading components 222 are controlled by the reader 230 system whichin turn communicates with the processor 232 of the mobile sensor packagerunning a control program.

The processor 232 is also in communication with a number of externalnetwork communications systems 234, such as Bluetooth, LTE-M, IP500,Wifi, shown in the sensor package 220 depicted in FIG. 10. The externalcommunications systems 234 interact using wireless communications withcorresponding communications systems 252 in the base station 250. Themobile sensor package 220 includes multiple external communicationssystems 234 so as to be compatible with many possible base stations 250and also to be able to select the type of wireless communication that isthe most appropriate to the type of action being undertaken. Forexample, if the base station is physically near, the mobile sensorpackage 220 will use low power Bluetooth. If the base station is furtheraway such that a Bluetooth connection is not feasible, the mobile sensorpackage could attempt to communicate using Wifi, or UWB.

While in the embodiment shown in FIG. 10 each connectivity system hasits own antenna, in other embodiments, a single antenna can be used tosend and receive different types of communications.

The mobile sensor package 220 also includes a power control system 236and a battery-based power source 238. The power control system 236 willplace the mobile sensor package 220 in a low power mode, unless themover which hosts the mobile sensor package 220 is actually performingan action. The power control system 236 ensures that unnecessarywireless hardware is not operating, thereby maximizing the battery 238life span.

In one embodiment the system seeks to optimize battery running time inbetween charges. In another embodiment, the system seeks to optimizebattery life over the life span of the battery. In another embodiment,the power saving features are optional, depending on the powercapabilities of the given environment.

The mobile sensor package 220 also includes the ability to measure itsown movement, as the embodiment shown in FIG. 10 includes an inertialmeasurement unit or IMU 240. The IMU 240 includes at least oneaccelerometer and at least one gyroscope to report the velocity andorientation of the mobile sensor package 220.

In some applications the sensor package 220 can obtain a reliable GPSsignal, such as if the host mover is used outdoors. As such, the sensorpackage 220 includes a GPS receiver 242, in one embodiment.

The mobile sensor package 220 processor 232 includes a general purposeCPU, memory, storage, and software designed to operate the components ofthe mobile sensor package 220. The processor 232 includes a directexternal interface 246, shown as the USB interface, in the embodiment ofFIG. 10. In other embodiments, the direct interface 246 comprises anEthernet connection or even a direct user input and output interfaceincluding a connection to a terminal where a user can interact with themodule directly.

In the embodiment shown in FIG. 10, the mobile sensor package 220 isconfigured using one of the external wireless connections, such as Wifi,by the user 272 interacting with the central server 270 which in turnsends instructions to the mobile sensor package 220.

The mobile sensor package 220 comprises components, such as anindependently operated computer that allows the sensor package 220 tooperate independently of the host mover.

The external interface 246 of the mobile sensor package 220 allowsadditional sensors to be added to the sensor package 220. In oneembodiment there are other sensors in the sensor package 220 that arenot used to read tags and identify inventory, but instead are used tocapture data about the environment through which the inventory orcontainer or mover moves. In one embodiment, the additional sensorstrack temperature, shock, vibration, humidity, dust and otherparticulates, chemical analysis.

The only requirement is that the processor 232 storage contain thenecessary drivers to interact with the additional sensor. In oneembodiment, if the processor 232 storage does not contain the driversfor a particular sensor, the mobile sensor package will communicate witha central server 270 to obtain the necessary software to operate theadditional sensor.

In this way, the mobile sensor package 220 is both fully functional atthe start, but also can be expanded as the needs of a particulardeployment require.

While in the embodiment shown in FIG. 10, the mobile sensor package 220is shown as having a GPS sensor 242, other location technologies canalso be used. An alternative location technology is described below.

Each mobile sensor package 220 is mounted in a rugged enclosure (notshown). However, the enclosure is transparent to radio signals. In oneembodiment, at least one mobile sensor package 220 is attached to a sideof an autonomous inventory control robot, which moves from shelf toshelf picking up inventory trays. In another embodiment, the sensorpackage 220 is placed inside any container, such as a plastic tray ortote or cardboard box. The sensor package reads the contents of thecontainer and can read nearby containers. For example in one scenario,the first container is traveling down a conveyor, and while it travelsdown the conveyor the container can also read other containers that itpasses. If the container is stationary in a storage area, it canidentify containers within its read radius. The location of thecontainer is determined by UWB anchors that can read the UWB tag that isbuilt into the MSP. In one embodiment, the container is also located byusing its RFID or bar code reader to read RFID tags or bar code tagsthat are positioned in known locations along the path that the containermight follow. As the container passes the tags, it reads them and canknow its location.

In one embodiment, most of the mobile sensor packages 220 are mounted oninventory movers. However, some are mounted in fixed locations, such asa specific known passage, a door, or facility dock.

Alternative Location Technology

In one embodiment, each mobile sensor package 220 shown in FIG. 10 alsocomprises an active ultra-wide band (UWB) tag. This UWB tag is used tolocate each mobile sensor package 220, and therefore to locate eachmover (shown in FIGS. 8 and 9) which acts as a host to the mobile sensorpackage 220. Each mobile sensor package 220 includes an active UWB tag,which are read by UWB readers dispersed throughout the facility hostingthe movers. The UWB readers are placed at known locations at thefacility, and the UWB readers report the location of each UWB tagpassing in proximity to the readers.

Using the signal strength and the known location of the UWB reader, thelocation of the mobile sensor package can be determined.

While in the description above the entire mobile sensor package includedthe UWB active tag, in another embodiment, a tag is placed directly on amover separate from the package or other sensors. The mover alsoincludes inventory tag components, such as the RFID reader components222 shown in FIG. 10.

The UWB readers dispersed within the facility communicate to a centraldata depository, which in turn is analyzed by one or more systems toprovide information about inventory status through dashboards, or otherAPI's.

Using this inventory management system, only a few UWB readers placedstrategically throughout a facility can provide constant informationallowing software to compute inventory status, while individual itemsare tagged with disposable passive means, such as passive RFID tags.

In one embodiment, the UWB readers communicate with one or more basestations, in another embodiment, the UWB readers communicate directlywith a storage system, such as a cloud-based log storage system.

Alternative positioning technologies include using dead reckoning bymeasuring the distance travelled from a known starting position, opticalpositioning using a camera, relying on a signal received by anultra-narrow band antenna, GPS, Wi-Fi triangulation, or any combinationof the above.

Antenna Arrays

As was explained above, the sensor module 220 includes two arrays ofantennas 226, 228. The configuration of the antenna arrays and thespacing of the antenna arrays is dependent on the area to be read andthe technical restrictions on mounting the antenna and possibleinterference. Mechanical devices and the software operating the analogswitches 224 shown in FIG. 10 shape the beam to maximize the detectionof containers being carried by a particular mover, such as a robot orforklift.

In one embodiment, the sensor module 220 is approximately 1 meter longand includes four patch antennas, which in turn allow for different beamshapes to emanate from the module.

Data Processing Steps

Data processing steps 300 of one embodiment are depicted in the flowchart shown in FIG. 11. The steps shown in FIG. 11 depict but some ofthe possible actions as data is collected by the mobile sensor package220 and transmitted over a network 260 shown in FIG. 10. In oneembodiment, the transmitted data is pruned (removing entries thatreflect lost communications or data that arrived too late to be useful)and stored in one or more servers 270. The software running on theservers 270 includes one or more analytics packages that monitor thedata for anomalies and alerts end users 272 when certain thresholds aremet, as well as responding to queries from the clients.

Further, data is frequently presented using visualizations. In oneembodiment, the data is shown to the end users 272 in the form of avirtual reality presentation that shows how the inventory is movingthrough a facility. In another embodiment, data from the serves 270 isintegrated into an augmented reality application that allowsauthenticated users to review the path of a tracked inventory itemthrough a facility.

The system allows the end users to both replay past events as well asmonitor inventory movement in real time.

As was described above, the mobile sensor packages include connectionsto external sensors. In one embodiment, the system is used to supervisethe conveyance of temperature sensitive inventory. In this embodiment,the server receives information about the location of each item, andalso its temperature, to ensure that temperature requirements are met.

In another embodiment, each mobile sensor package includes a camerawhich transmits both images and video, which allows the end user 272 toview the video feed of inventory items moving through a facility. In oneembodiment, this audiovisual signal is stored by the system and allowsfor visual monitoring of valuable inventory.

Turning to the details of the data flow 300 within a mobile sensorpackage 220, the mobile sensor package processor 232 (shown in FIG. 10),awaits the next command 302, in a starting state 302 (FIG. 11). One ofthe possible commands is to take a sample 304, in which case the MSP onthe host mover uses its identification means such as an RFID reader toidentify the nearby objects 306, and, in some embodiments, alsoestimates the location of the desired sample 308 and reads informationfrom sensors 310. The MSP on the host mover then assembles the datarecord 312 which is time stamped and sent to the mobile sensor packagebase station.

Another possible command is to update the code 314. The code is thendownloaded and its integrity is verified 316. The verification occursusing CRC checks or equivalent means in one embodiment. The software isthen installed 318.

Yet another command is to execute a shell script 320. The validity ofthe shell script is verified 322 and the script is executed 324.

As was described above the mobile sensor package includes power savingcomponents, and so one of the commands is to put one or more components(including nearly all) to a low power sleep mode 326. The sleep mode 326continues until the sleep mode is interrupted 328. In one embodiment,the default mode of the module is sleep, and interrupts 328 can bereceived from multiple sources such as the arrival of a message on oneof the wireless communications systems.

The above data processing steps are exemplary of the steps to be takenby the mobile sensor package. The key action for the mobile sensorpackage is both taking a sample of the inventory 304 and sending thedata to the central repository 312.

Facility Network

A representation of the physical network 260 from FIG. 9 is depicted inFIG. 12. The network comprises multiple mobile sensor packages 220,which in turn communicate with wireless mesh hubs 350. Each mobilesensor package 220 may be in communication with more than one mesh hub350. The mesh hubs in turn communicate with an on-premises concentrator352, which processes the data from the hubs 350 and forwards it to thecloud network 354, in the depicted embodiment. In another embodiment(not shown) the concentrator 352 sends the data directly to a server.

While the concentrator 352 is depicted as a separate component in FIG.12, in other embodiments, any hub 350 may also be designated as theconcentrator. In yet another embodiment, the concentrator 352functionality is integrated into the server. However, if the serverwhich processes the data is not on the premises of the facility (as isthe case of the embodiment in FIG. 12 which relies on a cloud link 354),the concentrator should be used to prevent the transmission ofredundant, incomplete, and incorrect data.

The communications paths 356 shown in the embodiment depicted in FIG. 12are bidirectional, in one embodiment. In another embodiment, some of thelinks are unidirectional, to prevent data cycles in the mesh topologyand to optimize spectrum use.

While in FIG. 12 the output of the concentrator 352 is a connection tothe cloud 354, the cloud 354 represents a public data storage andprocessing facility in one embodiment, a private set of servers andstorage devices, or a combination of both, in local or remote locations,in various embodiments.

Sample Processing Steps

Turning to FIG. 13, depicted therein are sample processing steps 370pursuant to one embodiment of the invention. With respect to theinfrastructure shown in FIG. 12, the sample processing steps of FIG. 13occur within the cloud 354 from FIG. 12.

The input to the system is a sample 372. Each sample is firstpreliminary processed 374 and cleaned to remove any transmission noise,and a topic is assigned to each sample 372. While the samples 372normally pass through a concentrator, certain pre-processing steps stillmay be required to address transmission errors, or eliminating redundantsamples 372, especially when multiple concentrators are providing inputto the sample processing steps 370.

The topics for each sample 372 include a classifier 376 and a processingqueue 378. The topics, in the depicted embodiment include ‘sampleevent,’ ‘object event,’ ‘location event,’ and ‘sensor event.’ Each topicis assigned a queue 378. The topic is handled 380 depending on itsproperties.

The handlers interact with application programming interfaces 382,allowing the end users to interact with the sample data.

Cooperative Multiple Tier System

As described above, the multi-tier system collects identity data usingRFID tags at the time of moving of a tagged object and an RFID reader inthe mobile sensor platform. The embodiment gathers location data usingthe UWB anchors, and in turn, forwards the data to a central processingpoint in the cloud or a local server.

In another embodiment, the system is attached to a robotic mover. Insome instances, the robotic movers comprise automated guided vehicles(AGV's). In this embodiment, the system gathers location data from therobot control system. This location data is likewise forwarded to thecloud or local server. In this way, the system can accommodate afacility that uses autonomous movers that already keep track of certaininformation, such as location within the premises. In instances wherethe inventory is being moved by a human staff member or a robotic moverwithout location sensors, the system will rely on location and readermodules built into the system. The high-level control and navigation andcoordination systems of multiple robots are used in one embodiment bythe system analogously to using the UWB anchors' cloud database forlocation data. The result is that the multi-tier system can assembleinventory tracking information, including a timestamp and the inventoryidentifier to create a complete database record.

Alternative Embodiment Supporting Human Interaction

In the embodiments described above, various means of moving products onthe premises are envisioned. In traditional warehouse situations, aforklift will retrieve a pallet containing products from a given shelf.Given that the amount of raising of the carriage and forks is known,along with the known the location of the truck on the premises, thesystem can extrapolate, with considerable precision, the exact shelflocation that the forklift truck interacted with. In one embodiment, themobile sensor platform is located on the forks of the forklift truck. Inthis embodiment, it is not necessary to interact with the internal stateof the truck as the vertical position is determined by the mobile sensorpackage.

Likewise, the position of an articulated arm or a gantry picker is alsoknown and recorded. When those electromechanical devices interact with awarehouse, their configuration is stored and recorded either directly orindirectly. Depending on the quality and quantity of sensors embedded inthe movers, the system can account for all (or nearly all) movementswithin the environment.

However, certain warehouses include valuable parts or products stored onshelves which cannot be interacted with easily using electromechanicalproduct moving tools. As shown in the embodiment 400 in FIG. 14, In suchinstances, warehouse workers 405 will store, retrieve, or otherwiseinteract with an inventory of products 412 from shelves 410. A workernear multiple shelves 410, such as at location 420, could retrieveproduct from any number of possible shelves 410.

Therefore, keeping track of the location of each warehouse worker 405 isnot sufficient. Instead, the system must also incorporate data fromsensors about the interaction of the workers 405 with the storagesystem. In one embodiment, each worker 405 will record an identifier ofeach shelf 410 that each worker has interacted with. For example, theworker 405 can scan a bar code or another unique identifier of eachshelf 410. However, this requires the worker 405 to interrupt theirworkflow and does not prevent workers from either accidentally orintentionally scanning an incorrect shelf 410 or by failing to scan theshelf 410 entirely.

In another embodiment, each warehouse worker is equipped with a mobilesensor platform that tracks the location of either one or both hands. Inone embodiment 450, shown in FIG. 15 the mobile sensor platform iscarried by the team member such that the RFID component of the mobilesensor platform might be mounted on the worker's arm, wrist, waist, orchest and can identify the load being stocked or retrieved; the UWBcomponent of the mobile sensor platform might be mounted on the worker'shand or hands in the form of a glove or wrist strap and such UWBcomponent can locate the position of the hand or hands with greatprecision in x, y, and z, determining the exact location in which theworker places the load or from which the worker picked the load. Themobile sensor platform comprises of a general-purpose computing device,power from a battery, RFID or other identifying reader, communicationselectronics, various software components, sensors for detectingconditions such as humidity, temperature, vibration, shock,acceleration, air quality, and airborne chemicals, and UWB or otherlocation generating components. These elements may be packaged in one ormore different physical containers and mounted onto one or more physicallocations on the worker's body.

In one embodiment, the glove 455 combination include cut resistancefeatures, such as an additional layer of fabric, which provides the endwearer with additional protection, beyond facilitating the trackingfeatures.

In one embodiment, the glove and sleeve combination comprise a singlepiece; in another embodiment, the sensors on each glove 455 fingers arecapable of separation.

In some embodiments, the fingers of the glove 450 also include sensors;however, in most instances, that level of sensory granularity is notnecessary. It is sufficient to know the x,y, and z position of the handor hands handling the inventory.

While in FIG. 14 the environment is depicted as having shelves 410, thesame principles apply to any warehouse storage container, such asproduct boxes stored inside bins. The embodiments discussed herein ashelpful in resolving ambiguity created by a warehouse worker who canpotentially interact with more than one product from a given physicallocation.

As shown in FIG. 16, in yet another embodiment 460, the glove could beextended or replaced with straps or other methods of affixing the mobilesensor platform (MSP) 465 to the location 464 approximating theshoulder, elbow, forearm, or wrist of the wearer of the extended glove462. Several alternative positions of the MSP are shown in FIG. 16.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the inventionwithout departing from its scope. While the dimensions and types ofmaterials described herein are intended to define the parameters of theinvention, they are by no means limiting, but are instead exemplaryembodiments. Many other embodiments will be apparent to those of skillin the art upon reviewing the above description. The scope of theinvention should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. In the appended claims, the terms “including” and“in which” are used as the plain-English equivalents of the terms“comprising” and “wherein.” Moreover, in the following claims, the terms“first,” “second,” and “third,” are used merely as labels, and are notintended to impose numerical requirements on their objects. Further, thelimitations of the following claims are not written inmeans-plus-function format and are not intended to be interpreted basedon 35 U.S.C. § 112, sixth paragraph, unless and until such claimlimitations expressly use the phrase “means for” followed by a statementof function void of further structure.

The embodiment of the invention in which an exclusive property orprivilege is claimed is defined as follows:
 1. A system for location ofassets on a premises comprising: identifiers attached to a group of oneor more assets; and mobile sensor packages wherein each said mobilesensor package comprises data processing, data exchange, and storagecomponents, a sensor for reading identifiers and each mobile sensorpackage further comprises location tool within the premises; wherein atleast one mobile sensor package is attached to each mover of assets onthe premises.
 2. The system of claim 1 wherein said location tool foreach sensor package comprises an ultra-wide band tag active tag andwherein said premises further comprises readers of said ultra-wide bandtags at known locations.
 3. The system of claim 1 wherein saididentifiers comprise passive RFID tags.
 4. The system of claim 1 whereinsaid mobile sensor package reader of identifiers comprises a glove forlocating interactions.
 5. The system of claim 4 wherein said array ofantennas is constrained to read just RFID tags in a specific nearbylocation.
 6. The system of claim 1 wherein said mobile sensor packageprovides to an external data store lists of assets being carried by themover carrying said mobile sensor package.
 7. The system of claim 6wherein said external data store also comprises a list of a time and alocation for each asset group.
 8. The system of claim 1 wherein saiddata exchange system comprises a wireless link between each mobilesensor package and the location system.
 9. The system of claim 8 whereinsaid system provides for current positions of assets within the premisesby combining each mobile sensor package data storage contents using thewireless link of each mobile sensor package.
 10. The system of claim 2wherein the readers of ultra-wide band tags are located in knownlocations within said premises.
 11. The system of claim 1 wherein saidlocation tool triangulates the location of each mobile sensor packagewhile said mobile sensor package is in motion.
 12. A method of trackingthe contents of a premises, the method comprising: attaching identifiersto a group of one or more assets; attaching mobile sensor packages toeach mover of assets on the premises; wherein each said mobile sensorpackage comprises data processing, data exchange, and storagecomponents, a sensor for reading identifiers and each mobile sensorpackage further comprises a location tool within the premises; taking aninitial inventory of stationary assets within the premises; movingassets within the premises only using movers which are equipped withmobile sensor packages; and reading the identifiers on the assets whilemoving said assets by a mover, recording the location of each group ofassets as each group of assets moves through the premises.
 13. Themethod of claim 12 wherein said location tool for each sensor packagecomprises an ultra-wide band tag active tag and wherein said premisesfurther comprises readers of said ultra-wide band tags at knownlocations.
 14. The method of claim 12 wherein said identifiers comprisepassive RFID tags.
 15. The method of claim 12 wherein said mobile sensorpackage reader of identifiers comprises a glove for locatinginteractions.
 16. The method of claim 15 wherein said array of antennasis constrained to read just RFID tags in a specific nearby location. 17.The method of claim 12 wherein said mobile sensor package provides to anexternal data store lists of assets being carried by the mover carryingsaid mobile sensor package.
 18. The method of claim 17 wherein said dataexchange system comprises a wireless link between each mobile sensorpackage and the location system.
 19. The method of claim 12 wherein saiddata exchange system comprises a wireless link between each mobilesensor package and the location system.
 20. The method of claim 12wherein the readers of ultra-wide band tags are located in knownlocations within said premises.